Powder compact removal device and powder press system

Abstract

To increase the production yield when semicylindrically shaped powder compacts are produced.SOLUTION: A powder compact take-out apparatus is a take-out apparatus for taking out, from a top of a die of a press machine, a plurality of powder compacts arranged in a plurality of rows and having a convex surface and a flat surface located on the opposite side of the convex surface. The powder compact take-out apparatus includes a first parallel bar extending in a first axial direction and having a plurality of first adsorption portions, a second parallel bar extending in the first axial direction and having a plurality of second adsorption portions, and a drive device that adsorbs the convex surfaces of the powder compacts arranged in two of the plurality of rows by the first and second adsorption portions. The first adsorption part and the second adsorption part face opposite sides. The drive device arranges the first parallel bar and the second parallel bar such that a plurality of powder compacts arranged in at least one row are positioned between the first parallel bar and the second parallel bar during the adsorption operation, in such a manner that the plurality of powder compacts arranged in the one row are adsorbed by the first adsorption portion, and the plurality of powder compacts arranged in the other row are adsorbed by the second adsorption portion.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present application relates to a powder compact removal device and a powder press system. [Background technology]

[0002] RTB sintered magnets (R is a rare earth element and must contain at least one selected from the group consisting of Nd, Pr and Ce, T is at least one transition metal and must contain Fe, and B is boron) are represented by the formula RFe 14 It is composed of a main phase of a compound having a B-type crystal structure, a grain boundary phase located at the grain boundaries of this main phase, and a compound phase formed by the influence of trace additive elements and impurities. RTB-based sintered magnets have a high residual magnetic flux density B r (Hereinafter, simply "B r ") and high coercive force H cJ (Hereafter, simply "H cJ ") and is known as the highest performance magnet among permanent magnets.

[0003] For this reason, RTB sintered magnets are used in a variety of motors in the automotive sector, including electric vehicles (EVs, HVs, PHVs), renewable energy sectors such as wind power generation, home appliances, and industrial sectors. RTB sintered magnets are an essential material for making these motors smaller, lighter, more efficient, and more energy-efficient (improved energy efficiency). RTB sintered magnets are also used in the drive motors of motor vehicles, and by replacing internal combustion engine vehicles with electric vehicles, they also contribute to preventing global warming by reducing greenhouse gas emissions such as carbon dioxide (reducing fuel and exhaust gas). In this way, RTB sintered magnets are making a significant contribution to the realization of a clean energy society.

[0004] RTB sintered magnets are manufactured through processes such as preparing alloy powder, press-molding the alloy powder to produce a powder compact, and sintering the powder compact.

[0005] RTB sintered magnets are widely used in permanent magnet synchronous motors. In such motors, for example, torque is generated by a rotating magnetic field formed by copper wire (windings) wound around the teeth of a stator. A number of RTB sintered magnets are attached to the rotor core, which is made of a soft magnetic material. Permanent magnet synchronous motors are classified into surface magnet type and embedded magnet type. For example, embedded magnet type motors use sintered magnets embedded in each of a number of openings (holes or recesses) formed inside the rotor core. The openings for embedding magnets inside the rotor core generally have a shape that includes a curved surface, such as a "cylindrical" or "arc" shape. This is because precise control of the distribution of magnetic flux passing through the rotor during the motor's rotational operation is necessary to improve the motor's performance, and the shape and arrangement of the sintered magnets are important.

[0006] Patent Document 1 discloses an example of such an RTB based sintered magnet. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] JP 2020-39251 A Summary of the Invention [Problem to be solved by the invention]

[0008] When a powder compact having a shape known as a "semi-cylindrical" or "arc-shaped" shape is produced using a press, the powder compact has both curved and flat surfaces, making it difficult to handle. In particular, if a portion of the curved surface of the powder compact is damaged or deformed during the process of removing the powder compact from the press or during a subsequent process, the production yield of the RTB-based sintered magnet decreases. This problem is not necessarily limited to the production technology for RTB-based sintered magnets, and can occur when various powder compacts having a shape known as a "semi-cylindrical" or "arc-shaped" shape are produced using a press.

[0009] The embodiments of the present disclosure provide a powder compact removal device and a powder press system that can solve such problems. [Means for solving the problem]

[0010] In an exemplary embodiment, the powder compact removal device of the present disclosure is a removal device for removing a plurality of powder compacts arranged in a plurality of rows, each having a convex surface and a flat surface located opposite the convex surface, from a die of a press machine, the removal device including: a first parallel bar extending in a first axial direction and having a plurality of first suction parts arranged to adsorb the plurality of powder compacts arranged in one row of the plurality of rows; a second parallel bar extending in the first axial direction and having a plurality of second suction parts arranged to adsorb the plurality of powder compacts arranged in the other row of the plurality of rows; and a drive device for driving the first parallel bar and the second parallel bar to perform an operation of adsorbing the convex surfaces of the powder compacts arranged in two rows of the plurality of rows by the first suction parts and the second suction parts. The first suction parts and the second suction parts face opposite directions. The driving device positions the first parallel bar and the second parallel bar so that, during the suction operation, a plurality of powder moldings arranged in at least one of the multiple rows are positioned between the first parallel bar and the second parallel bar, and adsorbs the plurality of powder moldings arranged in one of the multiple rows with the first suction section, and adsorbs the plurality of powder moldings arranged in another of the multiple rows with the second suction section.

[0011] In one embodiment, the first suction portions of the first parallel bar include upper suction portions for suctioning the powder compacts arranged in a certain row among the powder compacts arranged in the multiple rows, and lower suction portions for suctioning the powder compacts arranged in the other rows. The upper suction portions and the lower suction portions are alternately arranged along the first axial direction. The second suction portions of the second parallel bar include upper suction portions for suctioning the powder compacts arranged in yet another row among the powder compacts arranged in the multiple rows, and lower suction portions for suctioning the powder compacts arranged in yet another row. The upper suction portions and the lower suction portions are alternately arranged along the first axial direction.

[0012] In one embodiment, the drive device adsorbs a plurality of powder molding bodies arranged in a certain row among a plurality of rows of powder molding bodies arranged in a certain row with one of the upper and lower suction parts of a first parallel bar, adsorbs a plurality of powder molding bodies arranged in another row with one of the upper and lower suction parts of a second parallel bar, and then changes the positions of the first and second parallel bars.Then, the drive device performs an operation of adsorbing a further plurality of powder molding bodies arranged in another row with the other of the upper and lower suction parts of the first parallel bar, and adsorbing a further plurality of powder molding bodies arranged in another row with the other of the upper and lower suction parts of the second parallel bar.

[0013] In one embodiment, the driving device adsorbs the convex surfaces of each of the multiple powder moldings using a multiple number of first suction portions and a multiple number of second suction portions, and places the multiple powder moldings on a mounting surface with the flat surfaces of each of the multiple powder moldings facing downward.

[0014] In one embodiment, the device further includes a first auxiliary member extending in the first axial direction so as to face the first suction portions of the first parallel bar, and a second auxiliary member extending in the first axial direction so as to face the second suction portions of the second parallel bar. The drive device arranges the first parallel bar and the first auxiliary member such that the multiple powder compacts aligned in a row are positioned between the first parallel bar and the first auxiliary member, and arranges the second parallel bar and the second auxiliary member such that the multiple powder compacts aligned in a row are positioned between the second parallel bar and the second auxiliary member. The first auxiliary member restricts positional movement of the flat surfaces of the multiple powder compacts when the multiple first suction portions adsorb the convex surfaces, and the second auxiliary member restricts positional movement of the flat surfaces of the multiple powder compacts when the multiple second suction portions adsorb the convex surfaces.

[0015] In one embodiment, the thickness of the first parallel bar including the first suction portion is smaller than the spacing in the thickness direction of the powder compacts in an adjacent row, and the thickness of the second parallel bar including the second suction portion is smaller than the spacing in the thickness direction of the powder compacts in an adjacent row, and the driving device makes the size of the spacing between the first parallel bar and the second parallel bar larger than the thickness of each powder compact (1) before performing the suction operation.

[0016] In an exemplary embodiment, the powder pressing system of the present disclosure is a powder pressing system for producing a plurality of powder compacts having a convex surface and a flat surface located opposite the convex surface, and includes a press machine and any one of the powder compact removal devices described above. The press machine includes a die having a plurality of cavities for respectively forming the plurality of powder compacts, and an upper punch and a lower punch for pressing the powder filled in the plurality of cavities. The powder compact removal device moves the plurality of powder compacts formed by pressing the plurality of cavities with the upper and lower punches from above the die onto a mounting surface.

[0017] In one embodiment, in a top view, each of the plurality of cavities has a curve that defines a convex surface and a line segment that defines a flat surface of each of the powder compacts. The plurality of cavities includes cavities arranged along a first row, a second row, a third row, and a fourth row that are parallel to one another. The curves and line segments of the cavities arranged along the first and second rows are located on the same side of the center line of each row. The curves and line segments of the cavities arranged along the third and fourth rows are located on the same side of the center line of each row. The relationship between the cavities arranged along the first and second rows and the cavities arranged along the third and fourth rows is symmetrical. The curves of the cavities arranged in the second row are opposite to the curves of the cavities arranged in the third row. The powder compact removal device adsorbs the convex surfaces of the powder compacts formed in the cavities aligned along a first row of the multiple cavities with a first suction portion of the first parallel bar and adsorbs the convex surfaces of the powder compacts formed in the cavities aligned along a third row with a second suction portion of the second parallel bar, and removes the powder compacts formed in the cavities aligned along the first and third rows from above the die. The first suction portion of the first parallel bar adsorbs the convex surfaces of the powder compacts formed in the cavities aligned along a second row of the multiple cavities and the second suction portion of the second parallel bar adsorbs the convex surfaces of the powder compacts formed in the cavities aligned along a fourth row, and removes the powder compacts formed in the cavities aligned along the second and fourth rows from above the die and places them on a mounting surface so that the flat surfaces are in contact with the mounting surface. Effect of the Invention

[0018] According to an embodiment of the present disclosure, after producing various powder compacts having shapes such as those called "semi-cylindrical" or "arc-shaped" by a press machine, it is possible to place the powder compact with the flat part facing down on a mounting surface by sucking the curved part of the powder compact and performing a removal operation. As a result, it is possible to suppress deformation or damage of the powder compact and improve the manufacturing yield.

[0019] According to the embodiment of the present disclosure, since it is possible to efficiently remove a plurality of powder compacts arranged in a plurality of rows from the die of the press machine, it is possible to increase the arrangement density of the cavities in the die. Furthermore, when a magnetic field is applied to the die, it is possible to suppress disturbance of the magnetic flux and arrange the cavities densely. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a diagram illustrating a schematic configuration example of a powder pressing system according to an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a perspective view that illustrates a schematic configuration example of a powder compact produced by a press. [Diagram 3] FIG. 3 is a top view that illustrates an example of the arrangement of a plurality of cavities in a die. [Figure 4] FIG. 4 is a cross-sectional view showing a schematic arrangement of an upper punch, a die, and a lower punch during a pressing process. [Diagram 5] FIG. 5 is a cross-sectional view that illustrates a schematic arrangement of an upper punch, a die, and a lower punch during a pressing process. [Figure 6] FIG. 6 is a cross-sectional view that illustrates a schematic arrangement of an upper punch, a die, and a lower punch during a pressing process. [Figure 7] FIG. 7 is a cross-sectional view showing a schematic arrangement of an upper punch, a die, and a lower punch in a press machine. [Figure 8] FIG. 8 is a top view that illustrates a schematic configuration example of a powder compact removal device according to an embodiment of the present disclosure. [Figure 9] FIG. 9 is a side view showing a schematic configuration example of the powder compact removing device. [Figure 10] FIG. 10 is a top view showing a schematic operation of the powder compact removing device. [Figure 11] FIG. 11 is a top view showing a schematic operation of the powder compact removing device. [Figure 12] FIG. 12 is a top view that diagrammatically illustrates the operation of the powder compact removal device. [Figure 13] FIG. 13 is a top view that diagrammatically illustrates the operation of the powder compact removal device. [Figure 14] FIG. 14 is a top view that diagrammatically illustrates the operation of the powder compact removal device. [Figure 15] FIG. 15 is a front view showing a schematic operation of the powder compact removing device. [Figure 16] FIG. 16 is a front view showing a schematic operation of the powder compact removing device. [Figure 17] FIG. 17 is a front view showing a schematic operation of the powder compact removing device. [Figure 18] FIG. 18 is a front view showing a schematic operation of the powder compact removing device. [Figure 19] FIG. 19 is a front view showing a schematic operation of the powder compact removing device. [Figure 20] FIG. 20 is a front view showing a schematic operation of the powder compact removing device. [Figure 21] FIG. 21 is a front view showing a schematic operation of the powder compact removing device. [Figure 22] FIG. 22 is a front view showing a schematic operation of the powder compact removing device. [Figure 23] FIG. 23 is a plan view that shows a schematic example of the arrangement of powder molded bodies 1 placed on a placement surface 72. As shown in FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Hereinafter, embodiments of a powder compact removal device according to the present disclosure and a powder press system including the powder compact removal device will be described.

[0022] First, a configuration example of a powder press system according to an embodiment of the present disclosure will be described with reference to Fig. 1. Fig. 1 is a diagram that illustrates a configuration example of a powder press system 100 according to the present embodiment. The powder press system 100 includes a press machine 10 that produces a powder compact, and a powder compact removal device 20 that removes the powder compact produced by the press machine 10 from the press machine. For reference, the figure illustrates an X-axis, a Y-axis, and a Z-axis that are orthogonal to each other.

[0023] Next, an example of the configuration and operation of the press machine 10 in this embodiment will be described with reference to FIGS. 2 to 7 in addition to FIG.

[0024] Fig. 2 is a perspective view showing an example of the configuration of a powder compact 1 produced by a press machine 10. As shown in Fig. 2, the powder compact 1 has a convex surface 1a and a flat surface 1b located on the opposite side of the convex surface 1a, and has a shape known as a "cylindrical" or "bow (arc)" shape. Fig. 2 shows the length L, thickness T, and width W of the powder compact 1. In Fig. 1, the powder compacts 1 are arranged so that the direction of their length L is parallel to the Y-axis direction.

[0025] The press 10 in FIG. 1 includes a die 4 having a plurality of cavities for forming a plurality of powder compacts 1, and an upper punch 11 and a lower punch 12 for pressing the powder filled in the plurality of cavities. At least two of the upper punch 11, the lower punch 12, and the die 4 are driven by a driving device (not shown), so that the relative positional relationship between the upper punch 11, the lower punch 12, and the die 4 can be controlled. For example, the lower punch 12 may be fixed, and the upper punch 11 and the die 4 may be configured to move up and down independently. Alternatively, the die 4 may be fixed, and the upper punch 11 and the lower punch 12 may be configured to move up and down independently.

[0026] FIG. 3 is a top view showing a schematic example of the arrangement of a plurality of cavities 2 in a die 4. As shown in FIG. 3, the die 4 has a plurality of cavities 2 for respectively forming a plurality of powder compacts 1. In each cavity 2, the cross-sectional outline in a plane perpendicular to the Y-axis direction (plane parallel to the ZX plane) has a uniform shape along the Y-axis direction. In the die 4, both ends in the vertical direction (Y-axis direction) of each cavity 2 are open, and an upper punch 11 and a lower punch 12 are inserted from both ends. The upper punch 11 and the lower punch 12 have side surfaces that match the inner wall of the cavity 2, and the cross-sectional outline in a plane perpendicular to the Y-axis direction (plane parallel to the ZX plane) has a uniform shape along the Y-axis direction.

[0027] In the top view shown in Fig. 3, each of the multiple cavities 2 has a curve 2a that defines the respective convex surface 1a (see Fig. 2) of the powder compact 1 and a line segment 2b that defines the flat surface 1b (see Fig. 2). Moreover, the multiple cavities 2 in the example of Fig. 3 include cavities 2 arranged along a first row a, a second row b, a third row c, and a fourth row d that are parallel to each other. In Fig. 3, each of the rows a, b, c, and d is parallel to the Z axis, and seven cavities 2 are arranged in each row. The number of rows of cavities 2 that the die 4 has and the number of cavities 2 in each row are not limited to the example of Fig. 3.

[0028] 3, the curved lines 2a and the line segments 2b of the cavities 2 aligned along the first row a and the second row b are located on the same side of the center line (dashed line) of each row. More specifically, in the cavities 2 aligned along the first row a and the second row b, the curved lines 2a are located on the side closer to the axis of symmetry 4C passing through the center of the die 4, and the line segments 2b are located on the side farther from the axis of symmetry 4C.

[0029] The curved lines 2a and the line segments 2b of the cavities 2 aligned along the third row c and the fourth row d are located on the same side of the center line (dashed line) of each row. More specifically, the curved lines 2a of the cavities 2 aligned along the third row c and the fourth row d are also located on the side closer to the axis of symmetry 4C, and the line segments 2b are located on the side farther from the axis of symmetry 4C.

[0030] Thus, in the embodiment of the present disclosure, the relationship between the cavities 2 aligned along the first row a and the second row b and the cavities 2 aligned along the third row c and the fourth row d is symmetrical with respect to the symmetry axis 4C that crosses the center of the die 4. Note that the curve 2a of the cavities 2 aligned along the second row b faces the curve 2a of the cavities 2 aligned along the third row c.

[0031] A pair of alignment magnetic field application devices 16 are shown in Fig. 3. The die 4 is disposed between the pair of alignment magnetic field application devices 16. The alignment magnetic field application device 16 forms a horizontal alignment magnetic field along the X-axis direction. The distribution of magnetic flux due to the alignment magnetic field is symmetrical with respect to the symmetry axis 4C in Fig. 3, and it becomes possible to appropriately form a desired magnetic field inside each cavity 2.

[0032] 4 to 7 are cross-sectional views that typically show the relative positions of the upper punch 11, die 4, and lower punch 12 in each state of the pressing process. In the state shown in FIG. 4, the upper punch 11 is located away from the die 4. The lower part of the cavity 2 of the die 4 is blocked by the tip of the lower punch 12. In this state, the cavity 2 forms a space with an open top. Powder is filled into the cavity 2 from this open top. The powder is, for example, the alloy powder for an RTB-based sintered magnet described above.

[0033] The position of the upper punch 11 is lowered relative to the die 4 and the lower punch 12 in the state shown in Fig. 4, and the upper punch 11 is inserted into the cavity 2 from above. In this way, the powder is pressed and compressed inside each cavity 2. As a result, a powder compact 1 can be produced inside each cavity 2.

[0034] FIG. 5 shows a state in which powder is compression molded between an upper punch 11 and a lower punch 12 inside each cavity 2 to form a powder compact 1.

[0035] Thereafter, as shown in FIG. 6, the upper punch 11 and the lower punch 12 are raised relative to the die 4 and returned to a position away from the die 4. At this time, the die 4 may be lowered while the upper punch 11 and the lower punch 12 are kept stationary. In this way, most of the powder compacts 1 can be discharged from the cavity 2, and the powder compacts 1 can be arranged on the die 4. After this, by raising the upper punch 11, a state in which a plurality of powder compacts 1 are arranged on the die 4 can be obtained as shown in FIG. 7. In the example of FIG. 7, the upper end surface of the lower punch 12 is located lower than the upper surface of the die 4. Therefore, a recess is formed at the position of the cavity 2 on the upper surface of the die 4, and the lower end of each powder compact 1 is held by the wall surface of the recess. However, the upper end of the lower punch 12 and the upper surface of the die 4 may be located at the same position.

[0036] As described above, in this embodiment, the cavities 2 arranged in a plurality of rows are symmetrical with respect to the symmetry axis 4C that crosses the center of the die 4. This makes it possible to appropriately form a desired magnetic field inside each cavity 2. In this embodiment, the convex surfaces 1a of the powder compacts 1 formed by pressing the upper and lower punches 11 and 12 in the plurality of cavities 2 arranged symmetrically with respect to the symmetry axis 4C that crosses the center of the die 4 are removed from the press 10 by the powder compact removal device 20 described later, and placed on a mounting surface with the flat part of the powder compact 1 facing down. This makes it possible to suppress deformation or damage of the powder compacts 1 due to contact with each other during movement in a later process (for example, a sintering process). Furthermore, according to the study by the present inventors, it was found that deformation (warping) of the obtained sintered magnet can be suppressed by sintering the powder compact with the flat part facing down.

[0037] Next, an example of the configuration and operation of the powder compact extracting device 20 will be described with reference to FIGS.

[0038] First, a configuration example of the powder compact extracting apparatus 20 will be described with reference to Fig. 8 and Fig. 9. Fig. 8 and Fig. 9 are a top view and a side view, respectively, that typically show the configuration example of the powder compact extracting apparatus in this embodiment.

[0039] The powder compact removal device 20 is configured to move a plurality of powder compacts 1 formed by pressing with upper and lower punches 11, 12 in a plurality of cavities 2 from above the die 4 onto the placement surface. Specifically, as shown in FIG. 8 and FIG. 9, the device includes a first parallel bar 21 and a second parallel bar 22 extending in the first axis (Z-axis) direction. The first parallel bar 21 has a plurality of first suction portions 31 arranged so as to adsorb a plurality of powder compacts 1 arranged in one row among a plurality of rows of the powder compacts 1 arranged on the die 4. The second parallel bar 22 has a plurality of second suction portions 32 arranged so as to adsorb a plurality of powder compacts arranged in another row among a plurality of rows of the powder compacts 1 arranged on the die 4. The first suction portion 31 and the second suction portion 32 face in opposite directions. Specifically, in top view of FIG. 8, the suction surface of the first suction portion 31 faces in the positive direction of the X-axis, whereas the suction surface of the second suction portion 32 faces in the negative direction of the X-axis.

[0040] The surface on which the powder molded body 1 removed from the press 10 is placed may be, for example, the upper surface of a table, a stand, a carrier or case for transportation, a belt conveyor, or the like.

[0041] The powder compact extracting device 20 includes driving devices 51 and 52 that drive the first parallel bar 21 and the second parallel bar 22 to perform an operation of sucking the convex surfaces 1a of the powder compacts 1 arranged in two of the multiple rows by the first suction unit 31 and the second suction unit 32. The driving devices 51 and 52 arrange the first parallel bar 21 and the second parallel bar 22 so that the multiple powder compacts 1 arranged in at least one of the multiple rows are located between the first parallel bar 21 and the second parallel bar 22 during the suction operation. Then, the first suction unit 31 sucks the multiple powder compacts 1 arranged in one row, and the second suction unit 32 sucks the multiple powder compacts 1 arranged in the other row. An example of the operation of the driving devices 51 and 52 will be described in detail later.

[0042] 9, in this embodiment, the multiple first suction portions 31 on the first parallel bar 21 include upper suction portions that suction multiple powder moldings 1 arranged in a certain row among the multiple rows of powder moldings 1, and lower suction portions that suction multiple powder moldings 1 arranged in another row. In order to provide two air flow paths for suction within the first parallel bar 21, it is preferable that the upper suction portions and the lower suction portions are arranged alternately along the first axis (Z-axis) direction.

[0043] Further, the second suction portions 32 on the second parallel bar include upper suction portions for suctioning the powder compacts 1 arranged in another row among the powder compacts 1 arranged in the rows, and lower suction portions for suctioning the powder compacts 1 arranged in the still further row. Similarly, the upper suction portions and the lower suction portions are preferably arranged alternately along the first axis (Z-axis) direction.

[0044] The powder molding removing apparatus 20 in this embodiment further includes a first auxiliary member (41) extending in the first axis (Z-axis) direction so as to face the multiple first suction portions 31 of the first parallel bar 21, and a second auxiliary member (42) extending in the first axis (Z-axis) direction so as to face the multiple second suction portions 32 of the second parallel bar. The functions of the first auxiliary member (41) and the second auxiliary member (42) will be described later.

[0045] Next, an example of the configuration and operation of the powder compact removing device 20 will be described in detail with reference to FIGS.

[0046] First, refer to Fig. 10. On the die 4, the powder compacts 1 are arranged in a plurality of rows as shown in Fig. 10 (see Fig. 7). Specifically, the powder compacts 1 are arranged along a first row a, a second row b, a third row c, and a fourth row d that are parallel to one another. In this example, the number of powder compacts 1 is 7 x 4 = 28, and these are produced by a single pressing process using the press 10.

[0047] At the stage of the process of FIG. 7, the powder compact removal device 20 is located away from the die 4 in the negative direction of the Z axis, as shown in FIG. 10, for example. Then, the driving devices 51 and 52 move the first parallel bar 21 and the second parallel bar 22 in the positive direction of the Z axis. As a result, as shown in FIG. 11, the first parallel bar 21 and the second parallel bar 22 are arranged so that the multiple powder compacts 1 arranged in the second row b are located between the first parallel bar 21 and the second parallel bar 22. More specifically, the position of the first parallel bar 21 in the Z axis direction is determined to be a position where the first suction portion 31 can adsorb the multiple powder compacts 1 arranged in the first row a. Similarly, the second parallel bar 22 is determined to be a position where the second suction portion 32 can adsorb the multiple powder compacts 1 arranged in the third row c. At this stage, a gap exists between the first adsorption portion 31 and the powder compact 1, and a gap also exists between the second adsorption portion 32 and the powder compact 1.

[0048] The driving device 51 positions the first parallel bar 21 and the first auxiliary member 41 such that the multiple powder compacts 1 aligned in the first row a are positioned between the first parallel bar 21 and the first auxiliary member 41. Similarly, the driving device 52 positions the second parallel bar 22 and the second auxiliary member 42 such that the multiple powder compacts 1 aligned in the third row c are positioned between the second parallel bar 22 and the second auxiliary member 42.

[0049] Fig. 15 is a front view showing the positional relationship between the powder compact 1 and the first and second parallel bars 21, 22 at this stage. Here, the "front view" refers to a view of an object viewed from the positive side of the Z axis in Fig. 14 to the negative side, for example, with the positive direction of the Y axis aligned vertically upward. The same applies to Figs. 16 to 22.

[0050] As is clear from FIG. 15, the size of the interval between the first parallel bar 21 and the second parallel bar 22 is larger than the thickness of the powder compact 1 at the stage immediately before the suction operation is performed. Also, the thickness of the first parallel bar 21 including the first suction portion 31 (the size in the direction parallel to the thickness direction of the powder compact 1) is smaller than the interval in the thickness direction of the powder compact 1 in the adjacent row. Similarly, the thickness of the second parallel bar 22 including the second suction portion 32 is smaller than the interval in the thickness direction of the powder compact 1 in the adjacent row. Thus, in this embodiment, two parallel bars 21 and 22 are inserted between the powder compacts 1 in the adjacent rows. The first suction portion and the second suction portion face opposite directions, and the driving device arranges the first parallel bar 21 and the second parallel bar 22 so that the multiple powder compacts 1 arranged in at least one row of the multiple rows are located between the first parallel bar 21 and the second parallel bar 22 during the suction operation. That is, the two parallel bars 21 and 22 are inserted so that the adjacent other rows are located between the row that is sucked by the first suction portion of the first parallel bar 21 and the row that is sucked by the second suction portion of the second parallel bar 22. This creates a gap between the parallel bars 21 and 22 that is at least the width of the other rows. In contrast, if an operation of sucking the convex surfaces 1a of the powder compacts 1 arranged in the second row b by the first suction portion of the first parallel bar 21 and an operation of sucking the convex surfaces 1a of the powder compacts 1 arranged in the third row c by the second suction portion of the second parallel bar 22 are simultaneously performed, there is no adjacent other row between the row that is sucked by the first parallel bar 21 and the row that is sucked by the second parallel bar 22. In the case where the first parallel bars 21 and the second parallel bars 22 are adjacent to each other in this manner, when the powder compact 1 is removed from the press 10 or when the powder compact 1 is subsequently placed on a mounting surface, for example, the powder compact 1 adsorbed by the second suction portion of the second parallel bar 22 may come into contact with the first parallel bar 21 or with the powder compact 1 adsorbed by the first suction portion of the first parallel bar 21, resulting in chipping (damage). In addition, in order to prevent the occurrence of chipping, it is necessary to increase the distance between the second row b and the third row c so that the first parallel bars 21 and the second parallel bars 22 are not adjacent to each other.Such an increase in the interval between the rows is undesirable because it leads to an increase in the size of the die 4 of the press 10. If the die 4 is made larger, the press 10 will also be made larger, which may significantly increase the equipment costs. Furthermore, if the die 4 is made larger, it may be difficult to appropriately form the desired magnetic field. In contrast, in this embodiment, the first parallel bars 21 and the second parallel bars 22 can be arranged not to be adjacent to each other without increasing the size of the die 4, which makes it possible to suppress the occurrence of chipping when the powder compact 1 is removed from the press 10 or when the powder compact 1 is subsequently placed on a mounting surface.

[0051] Next, as shown in Fig. 16, a suction operation is performed. During the suction operation, when the multiple first suction sections 31 suction the convex surfaces 1a of the multiple powder compacts 1, the first auxiliary member 41 restricts the positional movement of the flat surface 1b of each powder compact 1. Similarly, when the multiple second suction sections 32 suction the convex surfaces 1a of the multiple powder compacts 1, the second auxiliary member 42 restricts the positional movement of the flat surface 1b of each powder compact 1. Such restriction of the positional movement can be realized by the driving devices 51, 52 moving the first auxiliary member 41 and the second auxiliary member 42 in the X-axis direction to bring them into contact with the flat surface 1b of the powder compact 1.

[0052] After this, as shown in FIG. 17, the powder compacts 1 in the first row a and the third row c rise in the Y-axis direction while being adsorbed to the first parallel bar 21 and the second parallel bar 22, respectively, and move away from the die 4. At this time, the powder compacts 1 are adsorbed to one of the upper and lower adsorption portions of the first adsorption portion 31 of the first parallel bar 21 and the second adsorption portion 32 of the second parallel bar 22. In other words, the powder compacts 1 are not adsorbed to the other of the upper and lower adsorption portions of the first adsorption portion 31 of the first parallel bar 21 and the second adsorption portion 32 of the second parallel bar 22. FIG. 12 shows such a state.

[0053] Thereafter, the positions of the first parallel bar 21 and the second parallel bar 22 are changed as shown in Fig. 13. Then, the other of the upper suction portion and the lower suction portion of the first parallel bar 21 adsorbs a further plurality of powder moldings 1 arranged in another row (second row b). Similarly, the other of the upper suction portion and the lower suction portion of the second parallel bar 22 adsorbs a further plurality of powder moldings 1 arranged in another row (fourth row d).

[0054] This series of operations is shown in Figures 18 and 19. Figure 14 shows a state in which the four rows of powder compacts 1 are adsorbed by the first parallel bar 21 and the second parallel bar 22. Thereafter, by the action of the drive devices 51, 52, the first parallel bar 21 and the second parallel bar 22 are moved from the position shown in Figure 14 in the negative direction of the Z axis while still adsorbing the multiple powder compacts 1.

[0055] Next, after the distance between the first parallel bar 21 and the second parallel bar 22 is enlarged as shown in Fig. 20, the first parallel bar 21 and the second parallel bar 22 are each rotated around their central axis (axis parallel to the Z-axis) as shown in Fig. 21. In this way, as shown in Fig. 22, the flat surface 1b of each powder compact 1 is made to face the mounting surface 72 of the table 70, and then the powder compact is placed on the mounting surface 72 so that the flat surface 1b is in contact with the mounting surface 72.

[0056] FIG. 23 is a plan view showing a schematic arrangement example of the powder compact 1 placed on the placement surface 72. As shown in FIG. 23, the convex surface 1a of each powder compact 1 faces upward. In this embodiment, the upper suction parts of the first suction part 31 of the first parallel bar 21 and the second suction part 32 of the second parallel bar 22 suction the center part of the powder compact 1, and the lower suction parts of the first suction part 31 of the first parallel bar 21 and the second suction part 32 of the second parallel bar 22 suction the center part of the powder compact 1. In other words, the height (position in the Y-axis direction) of the two parallel bars 21, 22 when the powder compact 1 is suctioned by the upper suction parts is lower than the height (position in the Y-axis direction) of the two parallel bars 21, 22 when the powder compact 1 is suctioned by the lower suction parts. For this reason, the height of the powder compact 1 suctioned by each parallel bar 21, 22 changes alternately along the Z-axis direction. As a result, by rotating each parallel bar 21, 22 as shown in Figures 21 and 22, the position in the X-axis direction of the powder compact 1 placed on the mounting surface 72 changes alternately along the Z-axis direction as shown in Figure 23. [Industrial Applicability]

[0057] The powder compact removal apparatus and powder pressing system disclosed herein can be used to manufacture permanent magnets used in a wide variety of applications, such as motors for electric vehicles (EVs, HVs, PHVs), motors for industrial equipment, and other motors, as well as home appliances.

Claims

1. 1. A powder compact removal device that removes a plurality of powder compacts arranged in a plurality of rows, each having a convex surface and a flat surface located opposite the convex surface, from a die of a press machine, comprising: a first parallel bar extending in a first axial direction and having a plurality of first suction portions arranged to suction the plurality of powder compacts arranged in one of the plurality of rows; a second parallel bar extending in the first axial direction and having a plurality of second suction portions arranged so as to suction the plurality of powder compacts arranged in another row of the plurality of rows; a drive device that drives the first parallel bar and the second parallel bar to perform an operation of adsorbing the convex surfaces of the powder moldings arranged in two rows among a plurality of rows by the first suction unit and the second suction unit; Equipped with The first suction portion and the second suction portion face opposite directions, the driving device arranges the first parallel bar and the second parallel bar such that, during a suction operation, the plurality of powder molded bodies arranged in at least one of the plurality of rows are positioned between the first parallel bar and the second parallel bar, and causes the first suction section to suction the plurality of powder molded bodies arranged in one of the plurality of rows, and causes the second suction section to suction the plurality of powder molded bodies arranged in the other row of the plurality of rows. Powder compact removal device.

2. the first parallel bars each include an upper suction portion for suctioning a plurality of powder compacts arranged in a certain row among the plurality of powder compacts arranged in the plurality of rows, and a lower suction portion for suctioning a plurality of powder compacts arranged in another row, the upper suction portion and the lower suction portion being arranged alternately along the first axial direction, the second parallel bars each include an upper suction portion for suctioning a plurality of powder compacts arranged in another row among the plurality of powder compacts arranged in the plurality of rows, and a lower suction portion for suctioning a plurality of powder compacts arranged in another row, and the upper suction portion and the lower suction portion are arranged alternately along the first axial direction.

2. The powder compact removal device according to claim 1.

3. The drive device is a plurality of powder compacts arranged in a certain row among the plurality of powder compacts arranged in the plurality of rows are adsorbed by one of the upper suction portion and the lower suction portion of the first parallel bar, and a plurality of powder compacts arranged in another row are adsorbed by one of the upper suction portion and the lower suction portion of the second parallel bar, and then Varying the positions of the first parallel bar and the second parallel bar; an operation of adsorbing a plurality of powder moldings arranged in yet another row with the other of the upper suction portion and the lower suction portion of the first parallel bar, and adsorbing a plurality of powder moldings arranged in yet another row with the other of the upper suction portion and the lower suction portion of the second parallel bar; 3. The powder compact removing device according to claim 1 or 2.

4. the driving device causes the plurality of first suction portions and the plurality of second suction portions to suction the convex surfaces of the plurality of powder molded bodies, placing the plurality of powder molded bodies on a placement surface such that the flat surface of each of the plurality of powder molded bodies faces downward; The powder compact removing device according to any one of claims 1 to 3.

5. a first auxiliary member extending in the first axial direction so as to face the first suction portions of the first parallel bar; a second auxiliary member extending in the first axial direction so as to face the second suction portions of the second parallel bar; Further comprising: the drive device arranges the first parallel bar and the first auxiliary member such that the plurality of powder compacts arranged in a row are positioned between the first parallel bar and the first auxiliary member during a suction operation, and arranges the second parallel bar and the second auxiliary member such that the plurality of powder compacts arranged in a row are positioned between the second parallel bar and the second auxiliary member; the first auxiliary member restricts positional movement of the flat surfaces of the powder moldings when the first suction portions suction the convex surfaces, the second auxiliary member restricts positional movement of the flat surfaces of the powder molded bodies when the second suction portions suction the convex surfaces. The powder compact removing device according to any one of claims 1 to 4.

6. a thickness of the first parallel bar including the first suction portion is smaller than a distance in a thickness direction between the powder compacts in an adjacent row, and a thickness of the second parallel bar including the second suction portion is smaller than a distance in a thickness direction between the powder compacts in an adjacent row, and the driving device makes a size of the distance between the first parallel bar and the second parallel bar larger than a thickness of each powder compact before performing a suction operation. The powder compact removing device according to any one of claims 1 to 5.

7. A powder press system for producing a plurality of powder compacts having a convex surface and a flat surface opposite to the convex surface, comprising: A press machine, The powder compact removal device according to any one of claims 1 to 6, Equipped with The press machine is a die having a plurality of cavities for forming the plurality of powder compacts, respectively; an upper punch and a lower punch for pressing the powder filled in the multiple cavities; Equipped with The powder compact removal device is the plurality of powder compacts formed by pressing the plurality of cavities with the upper and lower punches are moved from above the die onto a mounting surface; Powder pressing system.

8. In top view, each of the plurality of cavities has a curve that defines the convex surface and a line segment that defines the flat surface of each of the powder compacts; the plurality of cavities includes cavities aligned along first, second, third, and fourth parallel rows; the curved lines and the line segments of the cavities along the first and second rows are located on the same side of a center line of each row; the curved lines and the line segments of the cavities along the third and fourth rows are located on the same side of a center line of each row, respectively; the relationship between the cavities along the first and second rows and the cavities along the third and fourth rows is symmetrical, and the curve of the cavities along the second row is opposite to the curve of the cavities along the third row; The powder compact removal device is the first suction portion of the first parallel bar sucks the convex surface of the powder compact formed in the cavities aligned along the first row among the plurality of cavities, the second suction portion of the second parallel bar sucks the convex surface of the powder compact formed in the cavities aligned along the third row, and the powder compact formed in the cavities aligned along the first and third rows is removed from above the die; 8. The powder pressing system according to claim 7, wherein the first suction portion of the first parallel bar suctions the convex surfaces of the powder compacts formed in the cavities aligned along the second row of the plurality of cavities, and the second suction portion of the second parallel bar suctions the convex surfaces of the powder compacts formed in the cavities aligned along the fourth row, and the powder compacts formed in the cavities aligned along the second and fourth rows are removed from above the die and placed on the mounting surface such that the flat surface is in contact with the mounting surface.

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